Detailed Calculations and Discussion

Detailed Calculations:
1. Design pressure (P)
Given for CH4: Maximum gauge pressure= 1400 kPa = 13.82 atm ( 1kPa = 0.00987 atm) Pressure inside the tank = Maximum gauge pressure + atmospheric pressure = 13.82 + 1 atm = 14.82 atm The operating pressure = 14.82 -1 atm= 13.82 atm However, the design pressure is calculated at value 10 % higher than the operating pressure for safety considerations (Sinnot, 2005). Therefore, Design pressure (P)= 13.82 x 1.1= 15.202 atm = 15.20 atm (rounding off to two decimal places)

2. Material balance
Given the flow rate of the waste stream = 21,000 kg/hr In order to calculate the molar flow rate, it is required to calculate the average molar mass of the given feed stream. Components Methane (CH4) Ethanol (C2H6) P- Xylene (C8H10) Mole fraction in feed 0.15 0.15 0.70 Molar mass (g/mol) 16.04 46.07 106.16 Molar mass in feed (g/mol) 0.15 x 16.04=2.406 0.15 x 46.07=6.910 0.70 x106.16=74.312

Average molar mass (g/mol) = 2.406 + 6.910 + 74.312= 83.628 = 83.63 g/mol (round off to 2 decimal places) = 83.63 kg/kmol Molar flow rate of stream = Flow rate of waste stream (kg/hr)/ Average molar mass of feed (kg/kmol) = 21,000 kg/hr / 83.63 kg/kmol

= 251.106 kmol/hr = 251.11 kmol/hr (rounding off to two decimal places)

It is assumed that no p-xylene or ethanol is volatised in the flash tank and that CH4 insoluble in the liquid (Franks, 2014). Therefore, the CH4 is separated completely from the other two components. Consequently, The molar flow rate of CH4 that needs to be stored in the pressure vessel= 251.11 x 0.15 =37.67 kmol/hr

The methane is to be transferred to a pressure vessel using a compressor (C1). The compressor is expected to increase the temperature of the gas and the increase in temperature can be calculated assuming adiabatic compression. For methane, Adiabatic index ()=1.3 ; P1= 1 atm , T1 = 298 K , P2= 14.82 atm, T2= ? From P1V1=P2V2 In terms of temperature, P1 (1-)T1 () = P2 (1-) T2()

T2= 282.15 oC

Therefore, it is necessary to include a cool the gas before it enters the pressure vessel. The inclusion of a heat exchanger is suggested here. It is assumed that the heat exchanger included cools the gas down to a temperature of 400C before is sent to the pressure vessel. The pressure vessel design temperature is the maximum working temperature of the pressure vessel (Sinnot, 2005). The design temperature here is chosen as 500C to include the upper extreme of temperature expected in Victoria.

3. Preliminary Design
Assume: Cylindrical shell-Although pressure vessels are manufactured as spheres and cones also, however, cylindrical shells are easier to manufacture when compared to spherical pressure vessels and therefore more cost effective (Hearn, 1997). Initial diameter The initial diameter is taken as 3m which assists in easy transportation of the vessel from the manufacturer to the storage site (Franks, 2014). Aspect ratio The optimum ratio is taken as 3 which agrees with the optimum aspect ratio for the pressure range 0 1750 kPa (Franks, 2014) Flat plates vs. Domed ends Designing plat plates for a pressure of 1400 kPa would require a very high thickness compared to the design of domed ends, therefore it is decided to design with domed ends (Franks, Pressure vessel design).

Check capacity of vessel V= d2L)/4 = d2 x (3d)/4 =

d3 /4= 63.6255 m3 = 63.62 m3

To account for the real gas behaviour of methane, the compressibility factor needs to be calculated at the given temperature and pressure. For methane at 500C (The Engineering Toolbox), Tc= -82.30 C = -82.3 + 273 K = 190.85 K Pc= 4.64 MN/m2 = 4640 kPa T= 323 K P= 1400 kPa TR = T/TC = 323/190.85 = 1.69 PR= P/PC = 1501.3/4640 = 0.32 Using the values of TR and PR, the compressibility factor can be calculated for CH4 at 500C. Using the compressibility chart in given in the appendix A1 , the compressibility factor is found to be 0.97. Since the compressibility factor is very close to 1, ideal gas behaviour is assumed. No. of moles inside the pressure vessels (n) = PV/RT = (14.82atm x 63.62m3 )/ (82.05 x 10-6 atm m3 /molK x 323 K) = 35.58 kmol Mass (kg) = 35.58 kmol x 16.04 kg/kmol = 570.70 kg It is required that the methane in the storage facility is to be transported by the train once a day. Assuming that the train is delayed by 4 hours, the number of moles that will be stored in the tank as a result can be calculated. The no. of moles of gas per day (nd)= 35.58 kmol/hr x 28 hr = 996.24 kmol The no. of tanks thus required = nd/n = 996.24/35.58= 28 tanks V=nRT/P where V is the volume of the pressure vessel. V= (35.58 kmol x 8.314 kJ/kmolK x 323K)/ (101.3kPa/atm x 14.82 atm) = 63.64 m3 Dimension calculations:

V= L= V/( L= 9 m

/4) x L
2

/4) = (4x63.64 m3 )/ (3.142 x (3)2)

Check , L/D= 9/3 =3 which is the optimum aspect ratio. Since, CH4 is not very corrosive or toxic, therefore Carbon steel AS 1548-7-430 can be used to design the vessel (Franks, Pressure vessels Chapter 2)

4. Design of Shell
4.1. Shell thickness From table 3.3.1 (A), Design tensile strength at 500C (f) = 108 MPa Take corrosion resistance (c) = 2mm Start with class 3 vessel = 0.7 t=PD/ (2f P) = (1.54 x 3000) /(2 x 0.7 x108 1.54) = 30.86 mm Allowing a corrosion resistance of 2 mm , the total thickness (tt) = 32.86mm According to table 1.7 (Franks, Pressure vessels Chapter 2), for minimum shell thickness for class 2 and class 1 construction, it is required to use class 2 since tt >32 mm Therefore, reworking for class 2B construction with weld efficiency = 0.8 t= 25.38mm Allowing a corrosion resistance of 2.62 mm, we get a standard 28mm thickness. A double welded butt joint is recommended. Outside diameter (do) = 3000 + (2 x 28) =3056 mm Therefore, tt= 28mm , = 0.8 and double welded butt joint is suggested. Since, P= 1501.3 kPa, D= 3 m, From figure 1.3.1, AS 1210, it can be established that the vessel is indeed a pressure vessel. Consequently, it is required to register pressure vessel with Work Safe Victoria and also a design record needs to be kept. Also, a hazard analysis is required (Franks, Pressure vessels Chapter 2). According to AS 1692, For a vessel diameter =3 m, the minimum wall thickness = 10 mm. As the pressure vessel wall thickness = 28mm > 10 mm , the wall thickness is okay.

4.2. Hydrostatic testing In order to test whether the pressure vessel can withstand the pressure of the gas (test for strength) and also test for leaks. According to AS 1210, Ph= 1.5P X fh/f = 1.5 x 15.20 x 1 =22.8 atm (fh/f =1)

In conclusion, the preliminary measurements are tabulated below. Internal diameter Outer diameter Wall thickness 3000 mm 3056 mm 28 mm

5. End cap design

Since the design pressure > 1.5 MPa, Semi Ellipsoidal heads are chosen over torispherical head (Franks, Pressure vessels Chapter 2) Choosing a standard internal diameter of 3048mm SE and semi-ellipsoidal end cap and collecting relevant information from Australia Pressure Heads Pty Ltd., the thickness can be calculated using the formula t = PDK/ (2f P) ; K=1 , D/2h =2, = (1.540 x 3048 x 1) / ((2 x 108 x 0.80 ) -1.540) = 27.41 mm Allowing 2mm for corrosion resistance t= 29.41 mm which would require a 32mm end cap. It would be a good idea to try for another diameter here. For D= 2896 mm; K=1 , D/2h =2 t = PDK/ (2f P) = 26.04 mm Allow 1.96 mm for corrosion, tt = 26.04 + 1.96 = 28mm The material for the end cap is the same Carbon steel AS 1548-7-430 and a double welded butt joint is suggested.

Now, recalculating the thickness of the vessel with a new standard internal diameter, D=2896mm t= PD/ (2f P) = (1.540 x 2896) /((2x0.80x108 (1.54)) = 26.04 mm Allowing 1.96mm for corrosion, 28 mm standard thickness sheets can be used to make the shell. The pressure vessel is a thin walled pressure vessel since t <0.25D (28mm < 0.25 x 2896=724mm) Since we have changed the initial diameter, the aspect ratio will change. The new aspect ratio is given by: A=L/D= 9000/2896 = 3.10 which is still in the range for pressure vessels.

6. Aspect ratio of vessel with the end caps

From Australia Pressure Vessel Heads Pty Ltd, for 2896 ID SE Inner diameter (mm) Inner tangential height (mm) Straight flange (mm) Capacity (L) 2896 724 76 3173

L/D = (9000 + 2 x 724 + 2x 76 + 2x 28)/ (2896 + 2x28) = 3.61 Since this value still lies between 3 to 5, the aspect ratio is still fine.

7. Volume of pressure vessel and Overdesign

Volume of pressure vessel = Volume of shell + 2 x volume of end caps =( L)/4 + (2 x 3173 x 10-3 m3)

= (3.142x 2.8962 x 9)/4 + (2 x 3173 x 10-3) m3 = 65.63 m3 Initial volume = 63.62 m3 The percentage overdesign = (Volume of pressure vessel Initial volume) / (Initial volume) x 100

= (65.63 63.62/ 63.62) x100 = 3.15 % The overdesign allows for extra storage volume for methane and consequently more storage time in case the train runs late. The number of extra storage hours = 28 x 3.15/100 = 0.882 hours Therefore, total extra storage time = 4 + 0.88 = 4.88 hours This implies that the pressure vessels can hold methane up to approximately 29 hours just in case the train does not arrive in time.

8. Testing Procedures for Shell and End caps

According to table 1.6 given in AS 1210, these are the testing procedures that must be undertaken for class 2B vessels. Welding procedure qualification (AS/NZS 3992) Production of weld test plates (AS/NZS 3992) Hydrostatic testing at above calculated Ph = 22.8 atm

9. Nozzle design
9.1. Inlet Nozzle

9.1.1. Volumetric flow rate

The volumetric flow rate into the nozzle can be calculated at the operating pressure and temperature inside the tank. P= 14.82 atm , T= 500C , n= 37.67 kmol (calculated from material balance) , R= 82.05 x 10-6 atm m3 /molK V= nrt/p = 67.36 m3/hr Since the tanks are to be arranged in a tank farm, it is reasonable to assume that the tanks are arranged in 2 branches of 14 each and the volumetric flow is equally split between the two branches. Therefore , V (single branch) = 67.36/2 =33.68 m3/ hr 9.1.2. Inside Diameter of nozzle Diameter of nozzle can be calculated using: A = V (single branch)/v , where A is the area of the nozzle and v is the target velocity of methane ( 10m/s)

d2/4 = V (single branch)/ v => d= 34.5 mm Since, pipes are available only in standard sizes. Therefore, a schedule 80 (extra strong), DN 40 pipe is selected from the table given by Blue Scope Pipeline Supplies for the nozzle. Outside diameter (OD) = 48.3 mm Thickness (t) = 5.08 Internal diameter (ID) = OD -2t = 48.3 (2x5.08) = 38.14 mm Here, the target velocity should be checked with the pipe diameter. v= V/A= 0.0093/ ( x ID2/4) = (4x 0.0093) /(3.142 x (.038142))= 8.14 m/s Since, the recalculated velocity is within 5 -10 m/s which within the range of gas target velocities, therefore the diameter chosen is fine. NOTE: The nozzle is to be constructed of the same material as the shell and end caps i.e. Carbon steel AS 1548-7-430 9.1.3. Minimum thickness based on internal diameter t = (PD)/ (2fem P) Taking values of f ,e and m from table D2 in AS 4041 where, P=1.54 MPa , D= 0.03814m ,f=184 Mpa , e=1 , m=1 t= ( 1.54 x 0.03814) / (( 2 x 184 x 1 x1) 1.54)) = 0.1602 mm tm = t + G, where G is the sum of appropriate allowances G= Corrosion allowance + 12.5 % of tm Since methane is less corrosive, take corrosion allowance = 3 mm tm= 0.1602 + 3 + 0.125 x tm 0.875tm= 3.1602 tm = 3.61 mm , which is only less than the thickness required for standard strength DN 40 pipe (3.68mm) . Recognizing that methane is inflammable, it is decided to use the original schedule 80 (extra strong), DN 40 pipe for the nozzle to account for safety (in case of leaks , damage to the pipe).

9.2.

Outlet nozzle

In order to prevent a vacuum inside the pressure vessel, the pressure vessels should never be emptied completely i.e. some volume of methane should always be contained in the pressure vessel to maintain the pressure inside greater than the atmospheric pressure. It is assumed here that 10 % of the volume of the pressure vessel is always filled with methane which ensures that the pressure inside the vessel is always greater than the atmospheric pressure and the vessel doesnt collapse. Therefore the volume of the methane to be discharged (Vd)= 0.9 x volume of the vessel = 0.9 x 65.63 m3 = 59.07 m3

Supposing that the train which collects the methane stays for just 4 hours then in order to discharge all the methane in that time, the discharge time (dt) for each vessel is taken as 15 minutes and it is assumed that two tanks are discharged at one time. i.e. 15/60 hrs/tank x 28 tanks x 0.5 = 3.5 hours , the extra time of 0.5 hours could account for a buffer for unforeseen circumstances , for instance, if the train is late for half an hour. 9.2.1. Volumetric flow rate The volumetric flow rate of methane exiting the pressure vessel, Vout= Vd/dt = 59.07 m3/(15 min x 60 s/min) = 0.0656 m3/s 9.2.2. Internal diameter of nozzle

Vout/v = d2/4 = (0.0656 m3/s) / (10m/s) = d2/4 => d = 0.0914 m = 91.3 mm The closest diameter of a pipe corresponding to this nozzle size is found to be DN 100 (Blue scope pipeline supplies) .Similar to the pipe selected for the inlet nozzle, a schedule 80 (extra strong) pipe is chosen. For DN 100, Outside diameter (OD) = 114.3 mm Thickness (t) = 8.56 mm Inside diameter (ID) = OD 2t = 97.18 mm= 0.09718 m Here, the target velocity should be checked with the pipe diameter. v= V/A= 0.0656 m3/s/ ( x ID2/4) = (4x 0.0656) /(3.142 x (.097182))= 8.84 m/s Since the calculated target velocity lies in the range of 5- 10 m/s, it is concluded that the DN 100 pipe, can be used to connect to the outlet nozzle.

9.2.3. Minimum thickness based on internal diameter t = (PD)/ (2fem P) Taking values of f ,e and m from table D2 in AS 4041 where, P=1.54 MPa , D= 0.09718 m ,f=184 Mpa , e=1 , m=1 t= ( 1.54 x 0.09718) / (( 2 x 184 x 1 x1) 1.54)) = 0.408 mm tm = t + G, where G is the sum of appropriate allowances G= Corrosion allowance + 12.5 % of tm Since methane is less corrosive, take corrosion allowance = 3 mm tm= 0.408 + 3 + 0.125 x tm 0.875tm= 3.408 tm= 3.89 mm Here, using a Schedule 40 (standard pipe) is recommended because the thickness for the standard pipe is 6.02 mm which is greater than the minimum thickness we require. In conclusion, For the outlet nozzle Material: Carbon steel AS 1548-7-430 DN 100, Schedule 40 (standard) OD=114.3 mm , ID= 97.18 mm , t= 8.56mm , tm = 3.89 mm Material: Carbon steel AS 1548-7-430

10.

Flanges
A socket weld is preferred here over a butt weld as it is cheaper (Franks, Pressure vessel design). Since the design pressure and design temperature are 1540 kPa and design temperature is 500 C, Carbon steel pipe flanges, PN 20 Class 150 are chosen (ASME B 16.5). The flanges are chosen at the standard sizes corresponding to the pipe sizes calculated for the inlet and outlet nozzle, i.e. DN 40 , Schedule 80 and DN 100, Schedule 40 respectively. In conclusion, Type of weld : Socket weld

Class of material : PN 20 Class 150 Sizes and Strength: Inlet nozzle = DN 40 , Schedule 80 Outlet nozzle= DN 100, Schedule 40

11.

Welding

Since the pressure vessel is a class 2 vessel and has a higher weld efficiency (=0.8), a qualified welder will be required. Production of weld test plate will be required according to AS 3992. All requirements in table 1.6 (AS 1210) must be satisfied.

12.

Examination, Testing and Inspection.

All tests given in table 1.5 (AS 4041, 2006) for class 2B vessels should be carried out (Franks, Pressure vessel design). Inspection of the pipe is normally required according to table 1.5 (AS 4041, 2006) and is encouraged owing to the inflammable nature of methane gas.

13.

Supports

The pressure vessels can be oriented either horizontally or vertically, however a vertical orientation of the pressure vessels is suggested taking safety into consideration. The vessel height of 10.66 m introduces a risk of toppling and since the gas is inflammable, a horizontal orientation nullifies the risk.

14.

Saddle

Saddles are used to support the load of the pressure vessel. The saddle used for the pressure vessel is commonly made of concrete or steel plates and has a contact angle greater than 1200 but less than 1500 (Sinnot, 2005). For the pressure vessel designed, the contact angle is chosen as 1200 and the saddle support is to be designed according to the dimensions given in figure 13.26 (Sinnot, Coulson and Richardson).

14.1. Thickness of Saddle

15.

Reinforcing Manholes

Manholes are important for inspection and maintenance of the pressure vessels. Manholes of diameters 400-500 mm are common (AS 1210, table 3.20.9). From AS 1210, table 3.20.9, a manhole diameter of 500mm is chosen for the pressure vessel design. Diameter of manhole (dm) = 0.5m Area of manhole (Am) = dm2/4 = 0.196 m2

This area needs to be reinforced. The reinforced area (Ar) is calculated using the Equal area method (Franks, Pressure vessel design). Am = Ar 0.196 = Ar - 0.196 Ar = 0.392 dr2/4 = 0.392 dr = 0.706 m or 706 mm dr = 1.5 -2 dm (Franks, Pressure vessels Chapter 2) Checking, dr/dm = 706/500 = 1.41 which is reasonable. In conclusion, for the manhole, dm = 0.5m, dr = 0.706 m.

16.

Reinforcing Nozzles

Reinforcement to nozzles is provided with the help of Inset Nozzle method, in which the inlet and outlet nozzles are welded to the shell by welding at the four corners of the nozzle (i.e. at the base of the nozzle).

17.

Drainage Nozzles

Water is expected to be used both in cleaning of the vessel and in the hydrostatic testing of the class 2B pressure vessel. Therefore, the pressure vessel is to be equipped with a drainage nozzle according to section 8.16.1 of AS 1210. Assuming that it would take 20 minutes to drain all the water in the pressure vessel ad recognizing that the target velocity of water lies between 1.5 to 2.5m/s, the diameter of the drain nozzle can be worked out. Volume of water in tank= Volume of pressure vessel (V) = 65.63 m3 Volumetric flow rate (Vf) = (65.63 m3 )/ (20 min x 60 s/ min) = 0.0547 m3/s v= 2.5 m/s (taking the extreme end) Area of drain nozzle (Ad) = dd2/4 Now, Vf/v=A => (0.0547 m3/s) / (2.5 m/s) = dd2/4 dd= 0.167 m = 167mm The nearest pipe diameter from ASME B36.10 is DN 200. Outside diameter (OD) = 219.1 mm

Thickness (t) = 8.18 mm (schedule 40 standard strength) Inside diameter (ID) = OD 2t = 219.1 (2 x 8.18) = 202.74 mm Calculating the terminal velocity with this diameter, v= 4Vf/ ( (ID)2) = 1.7 m/s (which lies between the range 1.5-2 m/s for water) So, for the drainage nozzle, a Schedule 40 , DN 200 pipe is to be used. Also the material of the pipe is to be the same material as the rest of the vessel i.e. Carbon steel AS 1548-7-430. Also, to reinforce the nozzle, the inset nozzle method should be used. The flange should joined to the nozzle by means of a socket weld and should be made of the same material as the nozzle i.e. Carbon steel AS 1548-7-430.